PISTON, PIN SET - REPLACE

Operation 1028H60 · PISTONS AND CONNECTING RODS

3.0 24V V6

Dismantling

1. Remove the piston rings.

2. Release the pins (2a) and separate the connecting rods (2b) from the pistons (2c).

3. Remove the piston rings (3a) from the pistons using the tool (3b).

Reassembly

- Check the alignment of the connecting rods using suitable equipment; if it is not correct, replace the connecting rod.

- Check that the weight difference between the connecting rods, complete with half-bearings, caps and bolts corresponds to the recommended figures.

- The arrows in the diagram illustrate where material can be removed from the to equalize the weight.

- Check that the weight difference between the pistons corresponds to the recommended figures.

- Fit the circlips on the pistons using the tool.

1. Join the connecting rod to the piston so that the arrow (1a) stamped on the piston crown is facing the same way as illustrated in the diagram in relation to the lubrication port (1b) in the side of the connecting rod, also the bevel (1c) on the gudgeon pin should be facing to the lubrication port (1b).

- Fit the pin and secure it using the circlips.

2.0 16V JTD

Op. 1028H54 PISTON/CYLINDER LINER - R R

- Clean any carbon residues from the piston crown.

- Check that the weight difference between the pistons corresponds to the recommended figures.

- Slight machining in the areas for equalizing the weight is permitted.

1. Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.

- Check that the pin seat bore diameter is within specified values, otherwise replace the pin with an oversized pin.

- Check that the outer diameter of the piston pins corresponds to the recommended figures; if not, replace the worn components.

- Use a micrometer gauge to measure the thickness of the piston sealing rings.

The seals are available as spares in oversizes of - mm

1. Fit the sealing rings (1a) in the cylinder liner and use a feeler gauge (1b) to check the gap between the seal ends is within specified limits. Otherwise replace the sealing rings.

- Check the alignment of the connecting rods using suitable equipment; if it is not correct, replace the connecting rod.

- Check that the difference in weight between the connecting rods, complete with half-bearings, caps and bolts is within the recommended values.

- Slight machining in the areas for equalizing the weight is permitted.

- Check that the diameter of the big end and the small end are within the recommended values.

- Complete with

Op. 1028H54 PISTON/CYLINDER LINER - R R